Polymerization of unsaturated compounds having the cyclopentadiene nucleus



Patented Mar. 30, 1943 UNITED STATES PATENT OFFICE.

POLYMERIZATION OF UNSATURATED COM- POUNDS HAVING THE CYCLOPENTADIENE NUCLEUS Samuel G. Trepp, Swarthmore, Pa., assignor to The United Gas Improvement Company, a corporation of Pennsylvania No Drawing. Application June 17, 1938,

Serial No. 214,385

Claims.

characterized by being soluble in solvents such as benzene, toluene, chloroform, carbon tetrachloride and high flash naphtha, while the other is characterized by being insoluble in these solvents.

The polymerization is usually carried out while the cyclopentadiene is in solution in a. solvent.

I have discovered that the soluble type of polymer may be produced with aluminum bromideorganic solvent. complexes, an particularly aluminum bromide-ether complexes, by a careful control of the polymerizing reaction.

Examples of aluminum bromide complexes are aluminum bromide-nitrobenzene complex, aluminum bromide-acetylene complex, aluminum bromide-pentene complex, aluminum bromidediethyl ether complex, aluminum bromide-phenyl methyl ether complex, aluminum bromide-phen-v yl-ethyl ether complex, aluminum bromide-diisopropyl ether complex, and di-allgyl and aryl-alkyl ethers generally.

The preparation of complexes of this character in general comprises addin aluminum bromide to the solvent with agitation. As a result, if a reaction takes place, a definite chemical compound is formed.

There are at least four factors which influence production of soluble polymer. These four factors are (1) temperature, (2) concentration of cyclopentadiene, (3) proportion of uniformly distributed catalyst and (4) time.

Generally speaking, and all other conditions remaining the same, it appears that there is a threshold temperature for the formation of insoluble polymer, and that at all temperatures below this threshold temperature the soluble polymer results. It is recognized,thathigh concentrations of cyclopentadiene and/or high proportions of uniformly distributed catalyst might place this theoretical threshold temperature below commercially obtainable temperature levels. However, for reasonable concentrations of cyclopentadiene and reasonable proportions of uniformly distri-buted catalyst a threshold temperature can be shown to exist for any given concentration of cyclopentadiene with any given proportion of uniformly distributed catalyst. I

Also generally speaking, and all other condi tions remaining the same, it appears that there is a threshold concentration of cyclopentadiene for the formation of insoluble polymer, and that at all concentrations below this threshold concentration the solubleform of polymer results. The term concentration of cyclopentadiene" as used herein and in the claims specifies the percentage by weight of total cyclopentadiene, whether reacted or not, after all of the materials have been combined. It is recognized that inordinately high temperatures and/or inordinately high proportions of uniformly distributed catalyst may make. the theoretical threshold concentration dimcult of determination. However, for reasonable temperatures an reasonable proportions of uniformly distributed catalyst a threshold concentration of cyclopentadiene can be shown to exist at any given temperature with any given proportion of uniformly distributed catalyst. Also generally speaking, and all other conditions remaining the same, and assuming that all of the materials have been combined, it appears that there is a threshold proportion of uniformly distributed catalyst for the formation oi insoluble polymer, and that with all proportions below this threshold the soluble polymer results. Inthis connection experiments indicate quite clearly that catalyst is apparently used up during the polymerization of soluble polymer, and that additional catalyst is required to convert the soluble.

polymer into insoluble polymer. If the proportion of uniformly distributed catalyst is such that there is no catalyst available for the formation of insoluble polymer, none will be formed.

. shown to exist at any given temperature with any given concentration of cyclopentadiene.

Also generally speaking, and all other conditions remaining the same, it appearsthat there is a threshold reaction time for the formation of insoluble polymer, and that for all reaction times below'this threshold reaction time the soluble polymer results. It is recognized that low temperatures, low concentrations of cyclopentadiene, and/or low proportions of uniformly distributed catalyst may cause this theoretical threshold reaction time to approach infinity. On the other hand, .high temperatures, high concentrations of cyclopentadiene and/or high proportions of uniformly distributed catalyst may cause this theoretical threshold reaction time to approach zero. However, for reasonable'temperatures, for reasonable concentrations of cyclopentadiene, and/or for reasonable proportions of uniformly distributed catalyst, a threshold reaction time can be shown to exist.

When threshold conditions are just exceeded insoluble polymer is formed but not exclusively. This results in a mixture 'of soluble and insoluble polymers. When exceeding threshold conditions to a greater extent, however, insoluble polymer is formed exclusively. The band over which both soluble and insoluble polymers are formed varies in width with change in conditions. For instance this band decreases in width with increase in temperature.

- Furthermore, the exact values of (l) temperature, (2) concentration of cyclopentadiene, (3) proportion of uniformly distributed catalyst and (4) time at which insoluble polymer begins to-appear may vary somewhat with change in purity or source of cyclopentadiene or of cata-- lyst or a change in catalyst or solvent. However, the exact values may be readily determined by test.

The soluble polymer obtained varies in physical characteristics with the solvent used during the polymerization. For instance, soluble polycyclopentadienes obtained by polymerizing cyclopentadiene by my new process in solvent naphtha, toluene, or benzene differ somewhat from each other as shown, for example, in the suitability of these polycyclopentadienes for coating metals for which they are unusually well suited. As an illustration, for certain purposes the benzene polymer is superior, the toluene polymer coming next but being, nevertheless, particularly well suited. Accordingly, in the preparation of my polymerized cyclopentadiene a solution of cyclopentadiene in a chosen solvent such as toluene is employed.

I use as catalyst one or more aluminum bromide-organic solvent complex and particularly one or more aluminum bromide-ether complex.

The complex catalysts are preferably employed in the form of suspensions, emulsions, or solutions in organic solvents of which benzene, toluene, solvent naphtha and petroleum naphtha are examples. Such suspensions, emulsions, or solutions are formed by adding the catalyst to the solvent followed by stirring. As an example, I find that a concentration of aluminum bromide complex in toluene of 1.0% by weight of toluene is very suitable as a catalyst suspension although any other concentration or solvent suitable for the purpose maybe employed.

The reactants should not be combined too rapidly since under such circumstances the reaction may .proceed too violently and cause local overheating with the production of insoluble polymer, or undesirable color bodies, or both, which it is proposed to avoid.

While the catalyst may be added to the solution of cyclopentadiene particularly when the catalyst itself is in solution or in suspension in a solvent, I prefer to add the solution of cyclopentadienc to a suspension. emulsion or solution of the catalyst. This affords a more exact control of the amount and distribution of cyclopentadiene undergoing reaction at any one time. The reaction proceeds much more smoothly than when the-catalyst is added to the cyclopentadiene. In the latter case no reaction appears to take place until a certain catalyst concentration is reached whereupon the reaction proceeds at a very high rate, and may .get out of control.

In either event, however, the addition of one material to the other is preferably accompanied by thorough stirring which is preferably rapid to insure uniform distribution not only of the materials but also of temperature.

In addition the reaction is preferably carried out in apparatus capable of temperature control such as a jacketed vessel provided with an agitator.

A very effective control of the temperature of the reaction and of local superheating is aflorded when the preferred procedure is followed.

As an example, the proportion of catalyst may conveniently be between 1% to 5% by weight of cyclopentadiene provided the temperature of the reaction is controlled and/or the concentration of cyclopentadiene is sumciently low, thus avoiding the formation of insoluble polymer.

A proportion of catalyst of 3% by weight of the total cyclopentadiene present is found to be very convenient. It permits wide variation in temperatures and in concentrations of cyclopentadiene without danger of the formation of insoluble polymer. Furthermore, there is less likelihood of discoloration of the final product than if a larger proportion of catalyst were used.

Incidentally, it appears that the molecular weight of the resulting soluble polycyclopentadiene may be varied somewhat by varying the proportion of catalyst.

For instance, at all temperatures below 50 C. gel-like polymers are obtained when high proportions of catalyst are employed just below threshold conditions. The ease with which gellike polymers are obtained increases with decrease in temperature. These polymers are com pletely soluble.

Incidentally, the formation of gel does not indicate definitely the presence of insoluble polymer as shown above.

Discoloration of the product appears to increase and decrease with increase'and decrease in proportion of catalyst so that lower proportions of catalyst yield materials of lesser discoloration. I

Temperatures above C. are preferably avoided and it is recommended that great care be taken to keep the temperatures throughout the reaction below this point.

It is found that temperatures between --40 C, to 70 C. are suitable provided the reactants are sufliciently agitated or other steps taken to avoid local overheating. The preferred temperature range is between -40 C. and 30 C.

Incidentally, it appears that the molecular weight of the resulting soluble polycyclopentadiene may be varied somewhat-by varying the temperature.

The increase in color due to increased reaction temperature is quite noticeable at 45 C. and becomes very pronounced. as the reaction temperature approaches 100 C.

On the other hand, at C. and even though the proportion of catalyst is fairly high, surprisingly light. colored polymers are obtained.

Low reaction temperatures are therefore indicated.

Cyclopentadiene solutions of any suitable concentration can be used, keeping in mind what has been said with respect to threshold conditions, although I more often employ concentrations of cyclopentadiene of from 20 to 30% by weight of total reactants.

Incidentally, it appears that the molecular weight of the resulting soluble polycyclopenta-- diene may be varied somewhat by varying the concentration of cyclopentadiene in the starting material.

Under the recommended conditions the polymer is formed in good yield and with a satisfactory color.

The chosen time for the reaction may vary considerably keeping in mind what has been said about threshold conditions. I find that for practicable purposes and good yields other conditions should be chosen such that the reaction time is somewhere in the neighborhood of 2 hours or more. This is borne out by the fact that the yield increases with reaction time up to a certain point. The time is, of course, preferably chosen to obtain good yields.

The following specific example will serve to further illustrate the invention.

1.2 grams of aluminum bromide-diethyl ether complex, containing excess ether and containing I aluminum bromide about .85 gram by weight, are added to 150 grams of toluene with thorough agitation to form a suspension (emulsion or solution);

A mixture of 50 grams of cyclopentadiene and 50 grams of toluene are added to the suspension during the course of 5 minutes, the temperature being held between 13 C. and 18 C. during the addition by means of an ice bath. The mixture is then agitated at about C. for 3 hours, after which 10 cubic centimeters of 10% NazCOa is added. This is followed by vigorous agitation until hydrolysis is complete. The time necessary depends largely on the efiiciency of the agitation. I find, for instance, that agitating at 50 C. for one hour is sufiicient.

50 grams of quicklime (CaO) are now added to the reaction mixture followed by agitation for an additional hour. The materials are thus dried.

50 grams of a suitable filter aid are then added, and the mixture filtered.

A clear filtered solution containing 38 grams of polycyclopentadiene is thus obtained.

The catalyst employed in the above example was prepared as follows:

Anhydrous aluminum bromide was obtained by reacting'hot aluminum shavings with bromine vapor.

13.9 grams of the product thus produced was added to 5.4 grams of ethyl ether followed by vigorous stirring. This yielded 17.8 grams of aluminum bromide-ethyl ether complex diluted with 1.5 grams of excess ethyl ether. This quantity of excess ether was suflicient to maintain the catalyst fluid in which form it is somewhat easier to handle, although no difiiculty is experienced in handling pure aluminum bromide-ethyl ether complex which crystallizes in large colorless plates at about C.

Generally speaking, any other aluminum bromide-organic solvent complex might be substituted.

In the above specific example both the cyclopentadiene and the catalyst are in diluted form before addition. Furthermore, as pointed out above diluted cyclopentadiene i preferably added to diluted catalyst rather than vice verse. to afford a better control of the speed and uniformity of the reaction and of the amount of heat evolved and consequently the type of polymer produced. The reaction runs smoother and is much more easily controlled on a large scale.

The addition of water. or a water solution as above, to hydrolyze the catalyst makes it possible not only to completely remove the activity of the catalyst and thus stop th reaction at any point, but also makes it possible to remove the corrosive and disooloring acid constituents of the catalyst by a suitable alkali. The failure to substantially completely remove the catalyst and its hydrolysis products may be the cause of serious discoloration. The insoluble reaction products formed during the hydrolysis and neutralization remain behind on the filter leaving a highly purified filtrate. This polymer may be used as such, or it may be concentrated in a vacuum still of suitabl design to give a. product containing any desired higher concentration of polycyclopentadiene, or it might.

be diluted to give any desired lower concentration. or a second solvent might be substituted such as a higher boiling solvent. This may be done either before or after concentration by adding the second solvent and distilling.

In the above example the particular temperatures were chosen to control the physical properties such as viscosity and color of the product. It will be noted that at no time did the temperature exceed C. or even 70 C. The manner of combining the reactants, constant agitation, and brine cooling made it possible to prevent local overheating. and the formation of insoluble polymer.

In the above examples 1) temperature. (2) concentration of cyclopentadiene, (3i proportion of uniformly distributed catalyst, and (4) reaction time may be varied considerably in the production of soluble polymer having in mind what has been said with respect to threshold condi-.

tions. If it is found that insoluble polymer is obtained, one or more of the four conditions. nam ly (1) temperature, (2) concentration of cyclopentation with a solvent may be employed, if desired,

particularly in th case of highly viscous products. Generally speaking, for the formation of soluble polymer to the exclusion of insoluble polym r and/or extreme discoloration, temperature should rarely exceed 100 C. and preferably should not exceed 70 0., concentrations of cy-clopentadieoe should rarely exceed 50% by weight of the tctol solution except possibly at low temperatures. and concentrationspf uniformly distributed catalyst should rarely exceed 25% by weight of cyclopentadiene.

It should be kept in mind that there are for practical purposes minimum values for temperature, concentration of cyclopentadiene, proportion of catalyst and time, which practice will show ought to be exceeded to obtain reasonable yields. For instance, I find that when using ordinary commercial toluen as the solvent a certain quantity of aluminum bromide-ether complex per 100 grams cyclopentadiene is required before the reaction will commence. On the other hand, if the maximum values given in the previ ous paragraph for temperature, catalyst and cyclopentadiene were used simultaneously, insoluble polymer might be formed, even though the reaction time chosen were as short as good practice would permit.

It is by the observance of the preferred principles set forth herein that a quality product is produced in good yield.

While in the above specific example toluene is used as a polymerization medium, it is to be understood that other solvent may be substituted of which benzene, xylene, ethyl benzene, solvent naphtha, petroleum naphtha, carbon tetrachloride, and ethylene dichloride are examples. The

products with benzene and toluene are preferred for specific uses as hereinafter referred to.

Although in the above particular description both reactants, namely catalyst and unsaturated compound, are diluted prior to their admixture, it is to be understood that variations are possible.

For instance, it is conceivable that all of the diluent may be first mixed with one of the reactants (either catalyst or unsaturated compound) and that the other reactant may be added in concentrated form, particularly if the principles set forth herein are closely observed. Or the larger part of the diluent may be added to one of the reactants so that the other is relatively concentrated. It is also conceivable that, with the exercise of extreme care and the closest adherence to the principles set forth herein, both reactants might possibly be employed in relatively concentrated form. Other variations are possible.

when adding one liquid to another with agitation I find it convenient and often preferable to do this below the surface of one of the liquids.

Any other suitable alkali such as sodium hydroxide, sodium bicarbonate, magnesium hydroxide, an amine or other basic substance might be substituted for NaaCO: and/or quicklime in the above specific example, followed by a non-acidic drying agent such as Na2SO4, or soda lime. Both neutralization and drying is effected by CaO.

The product may be used for many purposes, for instance for lacquers generally, for varnishes either alone or in admixture with other resins, for enamels, for paints, or in fact for coating compositions generally. It is ideally suited to the coating of metals, for instance for the coating of food containers as described and claimed in copending application, Serial Number 291,007, filed August 19, 1939, by Newcomb K. Chaney. This is 'expecially true of the products polymerized in benzene and toluene.

If desired, it is possible to obtain soluble polycyclopent'adiene of higher viscosity or of otherwise changed characteristicsby starting with a solution of polycyclopentadiene and stopping the reaction before threshold conditions are exceeded.

While the invention has been particularly described in connection with the polymerization of cyclopentadiene, it is to be understood that it is applicable to the polymerization of substituted cyclopentadienes having the cyclopentadiene nucleus containing the characteristic conjugated double bonds. However, it is to be understood ,that the polymer particularly described has certain unique characteristics which distinguish it from polymers prepared from other starting materials. Examples of such other compounds are the alkyl, aryl, and alkyl-aryl.

It is to be understood that the above specific examples are by way of illustration. Therefore changes, omissions, additions, substitutions, and/ or modifications might be made within the scope of the claims without departing from the spirit of the invention which is intended to be limited only as required by the prior art.

I claim:

1. A process for producing benzene-soluble cyclic diene polymer by the catalytic polymerization of a cyclic diene compound selected from the class of cyclic dienes consisting of cyclopentadiene, alkyl substituted cyclopentadiene and aryl substituted cyclopentadiene in the substantial absence of polymerizable compounds not contained in said class, comprising mixing with said cyclic diene in the presence of a solvent to effect said polymerization in considerable proportion to said cyclic diene polymer a hydrolyzable aluminum bromide-organic solvent complex previously formed by reacting aluminum bromide with an organic solvent capable of reacting with aluminum bromide to form said hydrolyzable complex;

and preventing the polymerization of said cyclic diene from being eifected entirely to benzeneinsoluble cyclic diene polymer by thoroughly agitating the reaction mass while maintaining the reaction temperature below (2., the concentration of said cyclic diene below 50% by weight, and the proportion of catalyst to said cyclic diene below 25% by weight, and by stopping the reaction by inactivating said catalyst while benzene-soluble cyclic diene polymer is present in the reaction mass.

2. A process for producing benzene-soluble cyclic diene polymer by the catalytic polymerization of a cyclic diene compound selected from the class of cyclic dienes consisting of cyclopentadiene, alkyl substituted cyclopentadiene and aryl substituted cyclopentadiene in the substantial absence of polymerizable compounds not contained in said class, comprising mixing with said cyclic diene in the presence of a solvent to efiect said polymerization in considerable proportion to said cyclic diene polymer a hydrolyzable aluminum bromide-organic solvent complex previously formed by reacting aluminum bromide with an organic solvent capable of reacting with aluminum bromide to form said hydrolyzable complex; and preventing the polymerization of said cyclic diene from being eifected largely to benzeneinsoluble cyclic diene polymer by thoroughly agitating the reaction mass while maintaining the reaction temperature below 70 C., the concentration of said cyclic diene below 50% by weight, and the proportion of catalyst to said cyclic diene below 5% by weight, and by stopping the reaction by inactivating said catalyst while benzene-soluble cyclic diene polymer is the preponderant polymer present in the reaction mass. 3. A process for producing benzene-soluble polycyclopentadiene by the catalytic polymerize tion of cyclopentadiene in the substantial absence of polymerizable compounds other than cyclic dienes selected from the class of cyclic dienes consisting of cyclopentadiene, alkyl substituted cyclopentadiene and aryl substituted cyclopentadiene, comprising mixing with said cyclopentadiene in the presence of a solvent to effect said polymerization in considerable proportion to polycyclopentadiene a hydrolyzable aluminum bromide-organic solvent complex previously formed by reacting aluminum bromide" complex; and preventim the polymerization of said cyclopentadiene from being eflected entirely to benzene-insoluble polycyclopentadiene by thoroughly agitating the reaction mass while maintaining the reaction temperature below 70 C2, the concentration of said cyclopentadiene below 50% by weight, and the proportion of catalyst to said cyclopentadiene below 25% by weight, and by stopping the reaction by inactivating said catalyst while benzene-soluble polycyclopentadiene is present in the reaction mass.

e. A process for producing benzene-soluble polycyclopentadiene by the catalytic polymerization of cyclopentadiene in the substantial absence of polymerizable compounds other than cyclic dienes selected from the class of cyclic dienes consisting of cyclopentadiene, alkyl substituted cyclopentadiene and aryl substituted cyclopentadiene, comprising mixing with said cyclopentadiene in the presence of a solvent to effect said polymerization in considerable proportion to polycyclopentadiene a hydrolyzable aluminum bromide-organic solvent complex pre- 5. A process for producing'benzene-soluble polycyclopentadiene by the catalytic polymerization of cyclopentadiene in the substantial absence of polymerizable compounds other than cyclic dienes selected from the class of cyclic dienes consisting of cyclopentadiene, alkyl substituted cyclopentadiene, and aryl substituted oyclopentadiene, comprising mixing with said cyclopentadiene in the presence of a solvent to eflect said polymerization in considerable proportion to polycyclopentadiene a hydrolyzable' aluminum bromide-organic solvent complex previously formed by reacting aluminum bromide with an organic solvent capable of reacting with aluminum bromide to form said hydrolyzablebefore substantially any benzene-insoluble poly cyclopentadiene is present in the reaction. mass.

6. A process for producing benzene-soluble polycyclopentadiene by the catalytic polymerization of cyclopentadiene in the substantial absence of polymerizable material other than cyclic dienes selected from the class of cyclic dienes consisting of cyclopentadiene, alkyl substituted cyclopentadiene and aryl substituted cyclopentadiene,

.pentadiene below 50% comprising diluting said cyclopentadiene with a suitable solvent, diluting with a suitable solvent 8. hydrolyzable aluminum bromide-organic solvent complex previously formed by reacting aluminum bromide with an organic solvent capable of reacting with aluminum bromide to form said hydrolyzable complex, eifecting said polymerization in considerable proportion to polycyclopentadiene by slowly adding said solution of cyclopentadiene to said diluted catalyst with thorough mixing while maintaining the reaction temperature below 70 0., the concentration of said cyclopentadiene below 50% by weight, and the proportion of catalyst to said cyclopentadiene below 5% by weight, and stopping the reaction by inactivating said catalyst before substantially any benzene-insoluble polycyclopentaaluminum bromide-ether complex previously.

formed by reacting aluminum bromide with an ether capable of reacting with aluminum bromide to form said hydrolyzabie complex; and preventing the polymerization of saidcyclopentadiene from being efiected largely to benzene-insoluble polycyclopentadiene by thoroughly agitating the reaction mass while maintaining the reaction temperature below 70 C., the concentration of said cyclopentadiene below 50% by weight, and the proportion of catalyst to said cyclopentadiene below 25% by weight, and by stopping th reaction by inactivating said catalyst while benzene-solubl polycyclopentadiene is the preponderant polymer present in the reaction mass.

8. A process for producing benzene-soluble polycyclopentadiene by the catalytic polymeriza- 1 tion of cyolopentadiene in the substantial absence of all other compounds polymerizable under the conditions obtaining, comprising mixing with said cyclopentadiene in the presence of a solvent to effect said polymerization in considerable proportion to polycyclopentadiene a hydrolyzable aluminum bromide-organic solvent complex previously formed by reacting aluminum bromide with an organic solvent capable of reacting with aluminum bromide to form said bydrolyzable complex; and preventing the polymer- =ization of said cyciopentadiene from being offected entirely to benzene-insoluble polycyclopentadiene by thoroughly agitating the reaction mass while maintaining the reaction temperature below 0., the concentration of said cycloby weight, and the proportion of catalyst to said cyclopentadiene below 25% by weight, and by stopping the reaction by inactivating said catalyst while benzene-soluble polycyclopentadien is, present in the reaction massi 9. A .process for producing benzene-soluble polycyclopentadiene by the catalytic polymerization of oyclopentadiene in the substantial absence of all other compounds polymerizable under the conditions obtaining, comprising mixing with said cyclopentadiene in the presence of a solvent to effect said polymerization in consideri by weight, and by stopping the reactionby inactivating said catalyst while benzene-soluble polycyclopentadiene is the preponderant polymer present in the reaction mass.

10. A process for producing benzene-soluble polycyclopentadiene by the catalytic polymerization oi cyclopentadiene in the substantial absence of all other compounds polymerizable under the conditions obtaining, comprising mixing with said cyclopentadiene in the presence or an aromatic hydrocarbon solvent or less than 8 carbon'atoms to effect said polymerization in considerable proportion to polycyclopentadiene a hydroiyzable aluminum bromide-organic solvent complex previously formed by reacting aluminum bromide with an organic solvent capable of reacting with aluminum bromide to form said hydrolyzable complex; and preventing the polymerization of said cyclopentadiene from being eifected largely to benzene-insoluble polycyclopentadien by thoroughly agitating the reaction mass while maintaining the reaction temperaturebelow C., the concentration of said cyclopentadiene below by weight, and the proportion of catalyst to said cyclopentadiene below 5% by weight, and by stopping the reaction by, inactivating said catalyst while benzene-soluble polycyclopentadlene is the preponderant polymer 20 present in the reaction mass.

SAMUEL G. 'I'REPP. 

